Process for preparing a graft of dienestyrene-acrylate interpolymer with a vinyl carboxylic acid



Paul R. Van Ess, Berkeley, and Roy W.

PROCESS FOR PREPARENG A GRAFT F BIENE- STYRENE-ACRYLATE INTERPOLYMER WITHA `VINYL CARBOXYLIC ACID j Tess, (Brinda, Calif., assignorsvto Shell Oil Company, New York, NY., a corporation of Delaware No Drawing. Filed July 31, 1961, Ser. No. 127,796

9 Claims. (Cl. 2611-295) This invention relates to syntheticrlatex compositions which are interpolymers of polymerizable monomers. More particularly, the invention relates to the preparation of a latex .composition which isan interpolymer of, a styrene, an alkyl acrylate and/vor an alkyl methacrylate, a conjugated `diene and an Valpha-beta vinylidene carboxylic acid.

Specifically, the'invention-provides a process for preparing freeze-thaw stable and mechanically stable latex -which comprises adding a monomer mixtureV consisting essentially of. from to 20%;of a conjugated` diene, from 2%V lto 55% of a compound selected from the group consisting of `styrene and ring-substituted styrene, Vfrom to 87.5% of a compound selected from the group consistingof alkyl acrylates havingfrom 4to 12 carbon atoms, alkyl lriethacrylatesV having from 8 `to 16 carbon Vatoms and, mixtures thereof, and fromv 0.5% .to 5% by weight of the monomer mixture of an alpha-betal vinyli idene carboxylic acid to an aqueous emulsion comprising an emulsier land a free-radical initiator, and then maintaining the temperature of the reaction mixture with agitation between about 15 C. and 100 C. until at least 7 0%` conversion but less than 95% conversion is achieved,

t then adjusting the emulsion temperature to from Iabout 20 C. to 60 C.,Vand adding "from 0.05 to 10 parts per 100 parts of monomersof an alpha-beta vinylidene carboxylic acid,:then allowing the polymerization to proceed to substantial completion,` l y j Copolymers made from monoethylenic monomers containing a vinyl group in aqueous `emulsion. are known to be useful as surface coatings, paper coatings, and Jfor other Such flatices are particularly valuable for surf-ace uses. coatings or paints. Paints made `with alkyl acrylates have known advantages such asjscrub resistance, good exterior weather resistance, good color stability, and theA like, and such Ilms therefore possess certain superioritiesover other paint latices such as rubber latex compositions.

, However, the cost of the acrylate latices has been cornparatively-higher than with other monoethylenic monomers because more expensive monomers are required.

United States Patent O In general, acrylate latices contain a monomer which by itself would form a soft polymer such'as an alkyl` acrylate together withia monomerwhich by itself would l yield a hard polymer such as methyl methacrylate or styrene. However, certain diiculties are experienced in preparing latices utilizing styrene andalkyl Vacrylates which. .j have a satisfactory `freeze-thaw yand mechanic-al stability` and, at "the'same' time, can be made without excessive coagulation during the polymerization thereof. f

It is, therefore, an object ot'V the present inventionfto provide a process for preparing latices which have satis-.

3,202,627 Patented Aug. 24, 1965 NIce -ing Ifrom 8 to 16 carbon atoms Vand Ymixtures thereof, and

from 0.05% to 5% by weight of the monomer mixture of an alpha-beta vinylidene carboxylic acid, (2) an emulsier, (3) a free-radical initiator and then maintaining the temperature ofthe react-ion mixture' with agitation between about 15 C. and 100 C. until at least 70% conversion, but less than 95 conversion, is achieved, then adjusting the emulsion temperature to about '20 C. to

`" C., and adding fromV 0.05 to 10 parts per hundred parts of monomers of an alpha-beta vinylidene carboxylic acid, then allowing the polymerization to go to substantial completion.

It has also been discovered that this process -for copolymerizing ethylenically unsaturated monomers in aqueous emulsion provides latices which have good freezethaw stability and mechanical stability as well as good scrub resistance and good exterior weather'resist-ance. j

The monomer mixture of the present invention con- 4talus a conjugated diene, astyrene, anV alkyl acrylate and/or alkyl methacrylate, and an alpha-beta vinylidene carboxylic acid. Y

The conjugated dienes which are suitable for use in the present invention include, among others, butadiene, isoprene, pipery-lene, dimethylbutadiene, 4and ethylbutadiene.

In general, dienes having up to 8' carbon atoms .are pre- `ferred. j

Although styrene is preferred,,otherequivalents may be Aused in placeof all or part of the styrene.V Such equivalents include side chain-substituted styrene which may be substituted with alkyl and/ or halogengroups, such as,

vvfor example, alpha-methyl styrene and alpha-chlorostyrene, and nuclear or ring-substituted styrenes .wherem the' substituents` are alkyl and/or halogen groups, and preferably the alkyl styrenes having more preferably from 1 to4 carbon atomsl and/or halogen groups,such as, for exam- -ple, p-ethyl .styrene (-.1vinyl4ethylbenzene), `p-methyl styrene, p-butyl styrene, p-chloro styrene, 1-vinyl-2-ethy-ll 4-cnl-orobenzene, 1-vinyl-2,4-diethylbenzene and' l-vinyl- V2,4-diclllorolaenzene.

f In general, any alkyl acrylate having from 4 to 12 car- 50 acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate,

bon atoms may be used such as, 'for example, methyl any butyl acrylate and Z-ethylhexyl acrylate. However, the preferred acryl-etes 'are those in'which Vthe alkyl,- group has fromZ to 4 carbon atoms such as ethylpropyl and butyl.

v The alkyl acrylate may be replaced or substitutedin i part with an equivalent amount of analkyl methacrylate. V 4 In' gener-al, any alkyl methacrylate having from 8 to 16 carbon atoms may be used in lieu oi or mixed with the alkyl acrylate, such as, for example, butyl methacrylate,

` decyl -methacrylate octyl methacrylate, and lauryl meth-acfactory freeze-thaw and mechanical stability.v It is another object to provide a process for'preparing latices without excessive coagulation during polymerization. other object to provide a process for preparing acrylate rylate. Commercially available mixed methacrylates such .gas decyl-octyl meth-acrylate may also be used.

It is anlatices having good scrub resistance and good exterior.

lweather resistance.

while retaining the desirable properties. lt is a further object to provide a process for preparing latices which are particularly valuable for surface coatings and paints. Y

It is another object to pr-ovidea" process for preparing acrylate laticesmore economically In order to provide the desired copolymerizatiomit is `necessary to include as a comonomer an alpha-beta vinylidene carboxylic acid. It is also necessary to add the i same kor ,diferent `alpha-beta"vinylidene carboxylicV acid afterthe polymerization has proceeded to Vat least conversion, but less than conversion. Examplesof suitable alpha-beta vinyli-dene carboxylic 'acids include, among others, acrylic acid, methacrylic acid and itaconic acid. The amount of acid used in both the initial emulsion polymerization (usually in an emulsion premix) and after substantial conversion is achieved (at least 70%) will depend to some extent on the monomer system employed and on the equivalent weight of the acid. Thus, in general, the amount of acid used originally in the monomer mixture will be from about 0.5% to 5% by weight based on the total monomer and, for acrylic or methacrylic acid, the amount will be more generally from about 1% to 3% by weight of the total monomer. Likewise, the amount of acid to be added to the emulsion after 70% conversion, but less than 95% conversion, is obtained will kbe from about 0.05 to parts per 100 parts of monomer,

and preferably from about 1 to 5 parts per 100 parts of monomer. The polymerization is then -allowed to proceed to substantial completion, say, to about 97% or 98%. This period will generally range from a few hours to about 3 weeks depending upon the temperature, with a shorter time required at a higher temperature. Thus, at room temperature, about 10 days is generally required.

The reaction is carried out in an aqueous emulsion which -contains at least one anionic emulsier either alone or in combination with one or more nonionic emulsiiers. The anionic emulsiers are generally present a-t full concentration during the entire polymerization reaction and may include so-called water soluble anionic emulsiiiers and/or oil soluble anionic emulsifiers. The anionic emulsiliers include, among others, the potassium salt or other salts of sulfuric esters, alkane sulfonic acids and alkyl aromatic sulfonic acids. Typical anionic emulsiiiers include the alkali metal salt of an alkyl-aryl-polyethoxyethanol ysulfate and a representative sodium salt of alkylaryl-polyethoxy-ethanol sulfate is available commercially under the trade name of Triton 770. Other typical anionic emulsitiers include an alkyl ester of sulfosuc-cinic acid salt, such as, dihexyl ester of sodium sulfosuccinic acid which is available commercially und-er the trade name Aerosol MA; sodium alkyl aryl polyether sulfonate (Triton X-200); sodium lauryl sulfate; and the salts of alkly aryl sulfonic acid such as the ammonium salt of alkyl aryl sulfon'ic acid, which is available commercially under the trade name of Emcol P10-59. The amounts of eachanionic emulsiier will vary depending on the monomers, catalyst and specific emulsitiers used. However, it will generally be within the range of, say, 0.3

to 3% by Weight based on total monomer for each emulsifier.

The nonionic emulsifier may be present in part or not at all initially, with the remainder added during the process to improve the stability of the polymer particles as they .are formed. The nonionic emulsiiiers are composed of a hydrophobic or hydrocarbon portion and a hydrophilic portion which is a polyether chain usually terminated with an alcoholic hydroxyl group. Generally, the hydrophilic portion will contain repeating units of, say, `6-50 ether groups and hydrocarbon moieties of, say, about 7 to 12 carbon atoms. Particularly suitable is an octylphenol-ethylene oxide condensa-tion product which..

is commerciallyavailable under such trade names as Cpe-30 and Triton X-lOO. Other suitable products include those made by condensing ethylene oxide with alcohols such as nonyl, dodecyl, tetradecyl or alkylphenyls having alkyl groups of 6 to 15 carbon atoms. The amount of nonionic emulsier varies with the system, but it will generally be Within the range of, say, from 0.5 to 10% by weight based on total monomer.

.As indicated above, the polymerization must be carried rout in an emulsion in such a way that the monomers or polymers do not coagulate and which provide a stable product emulsion polymer. The emulsion polymerization system, therefore, must contain an effective catalyst system, which is preferably a free-radical initiator system. Any system that initiates free radicals is suitable for use in the present invention, such as, for example, high energy radiation, dissociative initiators, and redox systems. High energy radiation suitable for use in the present invention includes high energy electrons, protons and photons. Electron beams are suitably produced by electron -accelerators such as Ithe Van de Graaff, resonance transformers and linear accelerators or by a suitable arrangement of certain isotopes, eg., strontium 90. High energy photons suitable for use are, for example, X-rays.

The dissociative initiators include, among others, peroxygen initiators, lsuch as hydrogen peroxide, benzoyl peroxide and tertiarybutyl hydroperoxide and .azo and diazo compounds, such as azobisisobutyronitrile.

The preferred catalyst system is a redox ysystem which allows excellent control of the polymerization and enables the reaction to proceed smoothly at optimum reaction temperatures.

In the so-called redox system, the catalyst will be an oxidizing catalyst such as water soluble or partially water soluble hydroperoxide or persulfate. The catalyst then decomposes under the inuence of a reducing agent such as ferrous iron or sodium hydrosulte. The reaction is thus -controlled by keeping the temperature below the temperature where the peroxide or persulfate decomposes thermally and the desired decomposition effected by the addition of controlled amounts of reducing agent.

In a preferred form, a process is carried out by mixing the monomers together in the desired proportions, mixing water and one or more anionic emulsiers ror the anionic emulsiers together with part or all -of the nonionic emulsiliers to provide an emulsion consisting of the monomer mixture, emulsifying agent and the peroxide catalyst. A portion of the mixture is then treated with suicient reducing agent or activator to begin the reaction and allow the desired reacti-on temperature to be achieved. The further regulation is then elfected by controlled external cooling and by the addition of further emulsion and a proportionate addition of reducing agent to continue the reaction at the desired temperature and preferably from about 15 C. to 100 C. and more preferably from about 50 C. to 80 C. After the polymerization has progressed to about conversion and preferably to at least conversion, but less than 95% conversion, the emulsion is cooled to about room temperrature (20-30 C.). To the cooled emulsion from 0.05 to 10 parts per hundred parts of monomers of an alpha-beta vinylidene carboxylic acid -are then added and the polymerization is allowed to proceed to substantial completion or to at least 97.5% conversion. The emulsion is then made alkaline with ammonium hydroxide to a final pH of about 9. Additional stabilizers and/ or protective colloids brother additives may be added to protect the stable emulsion latex.

Residual monomer may be removed by steam stripping or by any known procedure for removing unreacted monomer. The latex is now ready for use in textile treating or lfor pigmentation to make pigmented paints or the like.

Acrylate latices, as normally prepared, are required to have a certain degree of stability. This stability is usually determined as ionic or electrolyte stability, mechanical stability and freeze-thaw stability.

Latices must be suiciently stable so that they are able to withstand the mechanical shearing stresses set up during routine handling. It they are not sufficiently stable, losses may be encountered through partial or, in the extreme case, complete gelation or coagulation. In some cases it may be ldesirable to actually grind pigment into a latex, and this would require good mechanical stability. The mechanical stability is usually determined by vigorous agitation in a mixer such as a Hamilton-Beach mixer for a period of, say, 30 minutes. If by visual examination the latex shows coagulation, the latex fails. If, on the 4other hand, no coagulum is observed, the latex is said to possess mechanical stability.

In the course of formulating paint from latex polymers, a wide variety of materials are used including pigments,

dispersants, wetting agents, fungicides, water and the like. Any one or all of these may introduce salts into the latex system. Therefore, it is desirable that the latex exhibits some degree of stability to salts. ln order to measure the resistance of the latex to electrolytes, various types of reagents are used, as for example, aqueous sodium chloride, V50% aqueous isopropyl alcohol, 5% aqueous calcium chloride and 5% aqueous alum (potassium aluminum sulfate). The test is conducted by mixing, as for example, -by shaking, equal volumes of latex and reagent. If no coagulation results after 24 hours, `the latex passes the ion stability test.

During normalshipment and use, latex is generally vprotected from freezing. However, this may not always g be possible; hence, it is desirable that any latex possess some resistance to freezing and thawing. As a test for acceptability, five cycles of alternate freezing and thawing for 24 hour periods are generally used. If the latex is not-affectedby such cycling, that is,'does not coagulate or gel, it is deemed to possess freeze-thaw stability.

`In -order to better illustrate the invention, the following `examples are given. The reactants, their proportions, and

other specific ingredients of the recipes are presented as being typical and various modifications can be made in view ofthe foregoing disclosure and discussion without departing from the spirit or scope of the disclosure or of the claims. centages disclosed in the examples are by'weight.

Example 1 l The, apparatus consisted of a conventional 'three-liter reaction tlask, with onel central yand four peripheral ground glass openings, fitted with a reux condenser, stirrer, thermometer., nitrogenngas inlet tube, a two-liter separatory funnel with 100 ml. graduations `and 250 ml. graduated dropping funnel. A monomer mixture was Vprepared by mixing the following ingredients'inV the proportions givenz' 121.7 g. (15.0%) of isoprene 284.03 g. (35.0%) of styrene 389.52 g. (48.0%) lof ethyl acrylate 16.23 g. (2.0%) of methacrylic-acid to three cycles of shaking and standing:

' 811.5 g. monomers 330 ml. distilled water V7.24 g. Erncol 'P10-59 (ammoniumrsalt of alkyl-,-aryl 'sulfonic acid) 8.12 g. OPE-30 l(octylphenol-ethylene oxide (11:30) condensation product, a solution of 25% solids) 8.12 g. Triton X-'10O (octyl-phenol-ethylene oxide (1:10) y condensation product, a solution of 25% solids) 1.8 ml. 25.% solution (NHQZSZO j 1.51 g. tertiarybutyl hydroperoxide (71% active ingre-l The reaction ilask was swept with nitrogen yand `435 ml. of distilled water and 480 ml. of emulsion premix vwere added. At this time 24.34 g. of OPE- (25%H solids) and 24.34 g. of Triton X-100 (25 solids) were Y also added `to the flask.

The kettle was cooled to `15 C. and 6.7 ml. of 9.1%

solution 4of Na2S2O4 and 1.8 ml. of 1% FeSO4-7H2O were added under nitrogen. The temperature was then raised to 70 C. and incremental additionof the emulsion premix was started and'` continued at a rate to maintainsrnooth reaction..

The balance of the feed emulsionV (ca. 820 ml.) was addedV over a period of 2 hours while maintaining .an average temperature of about 72 C. Reducing agent Unless otherwise speciiied, parts and per-Y 6 was added incrementally and proportionally to4 the amount of tetiarybutyl hydroperoxide being added via feed emulsion to maintain a steady supply of free radicals. The balance of the reducing agent was added in combination with nonionic surfactant in 145 ml; of a solution consisting of 11.6 ml. (12.4 g.) of 9.1% sodium hydrosullite solution, 24.34 g. (0.75 phm.) of a solution of -octylphenol-ethylene -oxide (1:30) condensation prod- A uct (25% solids) and 24.34Y g. (0.75 phm.) of a solution The freeze-thaw stability of the' `treated and untreated hours.

of Triton X400 (25% solids). This solution was introduced dropwise in such vamanner'that when all the emulsion premix hadbeen added, there remained 40 ml. of the original 145 ml. of Na2S2O4-nonionic solution in the separatory funnel. To ensure complete reaction, 0.50vg. of tertiarybutyl hydroperoxide (TBHP) and 0.3 ml. of

25% solution of ammonium per-sulfatewere added with concomitant addition of the balance ofLthe Na2S204- octylphenol-ethylene oxidesolution. The total dosage. of TBI-1P was 1.43 g. of 0.18 phm. of active ingredient. Digestion was continued one-half hour at ca. 72 C.

The total reaction mixture (1868 g.) was cooled to 25 C. and'iiltered through two layers of cheeseclotlL |The precoagulum, after washing and drying, `amounted to 45.0g. -or 5.5 phm. (parts per hundred Vpartsniononier). The total solids contentA was determined to be 37.0% compared to a calculated value of 44.65%, representing 83.1% conversion from monomer to polymer. The average particle Vsize in the latex was determined by the light transmission Vmethod to be labout-1000A. To 100 g. of the fresh, cooled, filtered llatex having'an 83.1% conversion, there Was added 4.20J'g. of a 10% solution of glacial methacrylic acid containing 0.025% methyl hydroquinone inhibitor. This represents 1 part of methacrylic acid per 100 parts' of monomer. Another 100 g. sample of the latex was Ataken but noiadditional metha-crylic acid was used. Both samples were then stored for ve days with the conversion being determined by total solidsfrom time to time. At the end of the ve days, the latex samples were adjusted toa pHJ-of 9.0 with ammonia and further evaluated. The resultsvare tabulated in the following table:

Y s Fresh latex plus Age, Fresh latex alone, l phm. metha days percent conversion crylic acid,

pereentconversion latex was determined by' subjecting' 8oz. samples tol 5 cycles of freezing and thawing, which cycles consisted of 24 hours at 20 C. and Q4 honrssat +25 C. At .the end ofeach cycle, the latex was visuallyexamined to determine if coagulation had occurred. AThe treated-latex passed 5 cycles without significant coagulation, Vwhereas the unreacted latex coagulated yafter only 1 cycle.- i

In order to evaluate the ion (electrolyte) stability of the latices, equa-l volumes (10;cc.) of latex and a reagent (5% `aqueous sodium chloride or 5% `aqueous :calcium or 5% laqueous alum) were shaken together for severalminutes and -were visu-ally inspectedY for coagulum after 24 i The treated latex exhibited no coagul-um when mixed with the three above-noted electrolyte solutions while the untreated 'latex'` coagulated withA all reagents.

The mechanical stability of the twol-laticeswas determined by placing a sampleof'the latexv '(200 mlg) in a four-quart, /s-inch ring diameter tin funnel whichhad the bottom sealed. The funnel containing the latex'was then placed under a' Number` Thirty v4Hamilton-Beach Drink Master 4-Fold Aerator. The standard impeller of f the aerator Was-.replaced with a flat Washer `2.97 cm. in diameter. The aerator was permitted vto runiat high speed until vthe latex coagulatesV or -for 30 minutes, whicheveris 7 shorter. If the latex coagulates before 30 minutes of this mechanical agitation, it is deemed to have failed the mechanical stability test. The treated latex passed by not coagulating lafter 30 minutes, whereas the untreated latex failed. The properties 'are `summarized below:

Fresh latex Properties Fresh latex plus 1 phm. alone meth acrylic acid Mechanical stability Passed. Freeze-thaw, cycles pa 5. Electrolyte stability Passed.

Thus, the latex treated with 1 phm. methacrylic acid possessed satisfactory freeze-thaw stability, electrolyte stability .and mechanical stability while the untreated latex failed these essential properties.

Example Il The procedure of Example I is repeated except that hexyl methacrylate is -substituted for the ethyl acrylate. A paint latex jis obtained which is stable when subjected to freezing and thawing, agitation and the addition of electrolytes.

Example III `81.15 g. (10%) of isoprene 324.60 g. (40%) of styrene 389.52 g. (48.0%) of ethyl -acrylate 16.23 g. (2.0%) of methacrylic lacid This monomer mixture was -then incorporated into an emulsion premix by adding the following material to the 'two-liter separatory funnel and subjecting the mixture to ,three cycles of .shaking and standing:

811.5 g. monomers 330 ml. distilled water `16.77 g. (0.62 phm.) of Triton 770 (sodium salt of alkyl aryl `polyethoxy-et-hanol sulfate, solution of 30% solids) 2.13 g. (0.21 phm.) of Aerosol MA (sodium dihexylsulfosuccinate, `80% solids) 8.12 g. (0.25 phm.) of OPE-30 (octyl-phenyl-ethylene oxide (1:30) condensation product, a :solution of 25% solids) 8.12 g. (0.25 phm.) of Triton X-100 (octyl-phenol-ethyl- .ene oxide (1:10) condensation product, a solution ofv 25 solids) 1.80 ml. (2.00 g.) 25% solution of `(NHQZSZO 1.51 g. tertiary butyl hydroperoxide (71% active ingredient) The reaction flask was swept with nitrogen and 435 ml. of distilled water and 480 ml. of emulsion premix were added. At this time 24.34g. of OPE-30 (25% solids) and 24.34 g. of Triton X-100 (25 solids) were also added.

The kettle was cooled to labout C. and `6.7 ml. (7.2 g.) of 9.1% .solution of Na2S'2O4 and 1.8 ml. of 1% -FeSO47H2O were added under nitrogen. The temperature was then raised to 7 0 C. and incremental addition :of lthe emulsion premix was started and continued at a rate to maintain smooth reaction.

The balance of the feed emulsion (ca. 800 ml.) was Iadded over a period of 2 hours while maintaining an average temperature of about 72 C. Reducing agent was added incrementally and proportionally to the amount of tertiarybutyl hydroperoxide being added via the feed emulsion to maintain a steady supply of free radicals. The balance of the reducing agent was added in combination with nonionic surfactant in a solution consisting of 11.0 ml. (11.8 g.) of 9.1% sodium hydrosulte solution, 16.22 g. (0.50 phm.) of a solution of octylphenol-ethylene oxide (1:30) condensation product l(25% solids) and 16.22 g. (0.50 phm.) of a solution of Triton X-100 (25 solids). This solution was introduced dropwise .as was done in Example I. Twenty drops (0.33 g.) of 71% TBHP and 0.3 ml. of 25% (NHQZSZO, were added to facilitate the reaction. Digestion was continued 1 hour at ca. 72 C.

The total reaction mixture (1810 g.) was cooled to 25 yC. and ltered through two layers of cheesecloth. The total solids content was determined to be 40.1% compared to .a calculated val-ue of 43.5%, representing 92% conversion from monomer to polymer. The average particle size in the `latex was determined by the light transmission Vmethod to be about `1020 A.

To 100 g. of this fresh, cooled, filtered latex was added 4.20 g. of a 10% solution of glacial methacrylic acid containing 0.025 methyl hydroquinone inhibitor. Another 100 g. sample of latex was taken and left untreated (no methacrylic acid added). After 5 days both latex samples were adjusted to a pH of 9.0 with ammonia and evaluated as to mechanical stability, freeze-thaw stability and electrolyte stability (5% aqueous solutions of NaCl, CaCl2 and alum). In all instances, the untreated latex coagulated under vigorous agitation in a Hamilton-Beach mixer, coagulated after only one freeze-thaw cycle and was unstable in the presence of the electrolyte solutions. The latex which had the methacrylic acid added passed all these tests.

Example V Example IV is substantially repeated except that an equivalent amount of itaconic acid is used in lieu of the methacrylic acid. Related results are obtained.

We claim as our invention:

1. A process for preparing freeze-thaw mechanical stable latex which comprises adding a minor portion of a monomer mixture consisting essentially of from 10% to 20% of a conjugated diene, from 2% to 55% of a corn- Vpound selected from the group consisting of styrene and ring-substituted styrene, from 20% to 87.5% of a compound selected from the group consisting of alkyl acrylates having from 4 to 12 carbon atoms, alkyl methacrylates having from 8 to 16 carbon atoms and mixtures thereof, and from 0.5% to 5% by weight of the monomer mixture of an alpha-beta vinylidene carboxylic acid to an aqueous emulsion comprising an emulsier and a freeradical initiator, and then adding incrementally during the polymerization the major portion of said monomer mixture while maintaining the temperature of the reaction mixture between about 15 C. and 100 C. until at least conversion but less than 95% conversion is achieved, then adjusting the emulsion temperature t0 from 20 C. to 60 C. and adding from 0.05 to 10 parts per 100 parts of monomer of an alpha-beta vinylidene carboxylic acid, then allowing the polymerization to proceed to substantial completion.

2. The process as in claim 1 wherein the temperature of the reaction mixture is maintained between about 70 C. and C. during at least 75% of the reaction period.

3. The process as in claim 1 wherein a minor portion of the vreaction mixture is rst brought together and the reaction temperature is adjusted between about 70 C.

sists of at least `one anionic emulsiiier and at least one` nonionic emulsier.

6. A process as in claim 7 wherein the emulsion is adjusted to a pH of 9.0 after adding from 0.05 to 10.0

parts per 100 parts of monomers of an alpha-beta vinylidene carboxylic acid. l

7. A process for preparing freeze-thaw mechanical stable latex which comprises adding a reducing agent in an amount suicient to. cause polymerizationto a minor portion of an aqueous emulsion containing (1) a monomer mixture consisting essentially of from to 20% of a conjugated diene, from 2% to 55% of a compound selected from the group consisting of styrene and ringsubstituted styrene, from 20% to 87.5% of a compound selected from the group consisting of an alkyl acrylate having from 4 to 12 carbon atoms, alkyl methacrylates having from 8 to 16 carbon atoms and mixtures thereof, and from 0.5% to 5% by weight of the monomer mixture of an alpha-beta vinylidene carboxylic acid, (2) an emulsier, and (3) an oxidizing agent, then adding during said polymerization the major portion of the emulsion in multiple additions while simultaneously keeping the temperature of the reaction mixturev between about C. and 85 C. until at least 70% conversion but less than 95% conversion is achieved, then adjusting the emulsion temperature to from C. to 60 C. and adding from 0.05 to 10.0 parts per 100 parts of monomers of an alphabeta vinylidene carboxylic acid, then allowing the polymerization to proceed to substantial completion.

8. A process for preparing freeze-thaw mechanical stable latex which comprises Vadding a reducing agent in an amount suicient to cause polymerization to a minor portion of an aqueous emulsion containing (l) a monomer mixture consisting of 15% butadiene, 35% styrene, 48% ethyl acrylateand 2% by Weight of methacrylic acid, (2) an emulsiier, and (3) an oxidizing agent,then adding during said polymerization the major portion of the emulsion in multiple additions While simultaneously keeping the temperature of the reaction mixture between j about C. and 75 C. until at least 80% conversion f acid then allowing the polymerization to proceed to at least 97.5%

9. A freeze-thaw stable and mechanical stable latex prepared by the process which comprises adding a reducing agent in an amount suicient to cause polymerization to a minor portion of an aqueous emulsion containing (1) a monomer mixture consisting essentially of from 10% to 20% of a conjugated diene, from 2% to 55% of a compound selected from the group consisting of styrene and ring-substituted styrene, from 20% to 87.5% of a compound selected from the group consisting of an alkyl acrylate having from 4 to 12 carbon atoms, alkyl methacrylates having from 8 to 16 carbon atoms and mixtures thereof, and from 0.5% to 5% by weight of the monomer mixture of an alpha-beta vinylidene carboxylic acid, (2) an emulsifier, and (3) an oxidizing agent, then adding during said polymerization the major portion of the emulsion in multiple additions While simultaneously` keeping the temperature of the reaction mixture between about 15 C. and 85 C. until at least 70% conversiony but less than conversion is achieved, then adjusting the emulsion temperature to from 20 C. to 60 C. and adding from 0.05 to 10.0 parts per parts of monomers of an alpha-beta-vinylidene carboxylic acid, then allowing the polymerization to proceed to substantial completion.

References Cited by the Examiner UNITED STATES i PATENTS 2,767,153 10/ 56 Sutton 260--29-6 2,837,444 6/58 Hahn 260-29.6 2,847,404 8/58 Hoertz 260-29.7 2,868,754 l/ 59 Eilbeck et al. 260-29.7 2,889,236 6/59 Hahn 26029.6 2,962,465 11/ 60 Lindstrom et al 260-29.6

MURRAY TILLMAN, Primary Examiner.

LEON BERCOVITZ, WILLIAM SHORT, Examiners. 

1. A PROCESS FOR PREPARING FREEZE-THAW MECHANICAL STABLE LATEX WHICH COMPRISES ADDING A MINOR PORTION OF A MONOMER MIXTURE CONSISTING ESSENTIALLY OF FROM 10% TO 20% OF A CONJUGATED DIENE, FROM 2% TO 55% OF A COMPOUND SELECTED FROM THE GROUP CONSISTING OF STYRENE AND RING-SUBSTITUTED SSTYRENE, FROM 20% TO 87.5% OF A COMPOUND SELECTED FROM THE GROUP CONSISTING OF ALKYL ACRYLATES HAVING FROM 4 TO 12 CARBON ATOMS, ALKYL METHACRYLATES HAVING FROM 8 TO 16 CARBON ATOMS AND MIXTURES THEREOF, AND FROM 0.5% TO 5% BY WEIGHT OF THE MONOMER MIXTURE OF AN ALPHA-BETA VINYLIDENE CARBOXYLIC ACID TO AN AQUEOUS EMULSION COMPRISING AN EMULSIFIER AND A FREERADICAL INITIATOR, AND THEN ADDING INCREMENTALLY DURING THE POLYMERIZATION THE MAJOR PORTION OF SAID MONOMER MIXTURE WHILE MAINTAINING THE TEMPERATURE OF THE REACTION MIXTURE BETWEEN ABOUT 15*C. AND 100*C. UNTIL AT LEAST 70% CONVERSION BUT LESS THAN 95% CONVERSION IS ACHIEVED, THEN ADJUSTING THE EMULSION TEMPERATURE TO FROM 20*C. TO 60*C. AND ADDING FROM 0.05 TO 10 PARTS PER 100 PARTS OF MONOMER OF AN ALPHA-BETA VINYLIDENE CARBOXYLIC ACID, THEN ALLOWING THE POLYMERIZATION TO PROCEED TO SUBSTANTIAL COMPLETION. 